US20090030116A1 - Method and Composition for Producing an Item - Google Patents

Method and Composition for Producing an Item Download PDF

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Publication number
US20090030116A1
US20090030116A1 US11/887,645 US88764506A US2009030116A1 US 20090030116 A1 US20090030116 A1 US 20090030116A1 US 88764506 A US88764506 A US 88764506A US 2009030116 A1 US2009030116 A1 US 2009030116A1
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United States
Prior art keywords
fibres
composition according
item
oxidizing agent
approximately
Prior art date
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Abandoned
Application number
US11/887,645
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English (en)
Inventor
Raffaella Di Girolamo
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
EUREKA PROJEKT per i servizi Srl
Original Assignee
Keiper Holding SRL
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Filing date
Publication date
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Assigned to KEIPER HOLDING S.R.L. reassignment KEIPER HOLDING S.R.L. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DI GIROLAMO, RAFFAELLA
Assigned to EUREKA PROJEKT SOCIETA A RESPONSABILITA LIMITATA PER I SERVIZI reassignment EUREKA PROJEKT SOCIETA A RESPONSABILITA LIMITATA PER I SERVIZI ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KEIPER HOLDING S.R.L.
Publication of US20090030116A1 publication Critical patent/US20090030116A1/en
Abandoned legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/006—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing mineral polymers, e.g. geopolymers of the Davidovits type
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/52—Sound-insulating materials
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/10—Production of cement, e.g. improving or optimising the production methods; Cement grinding
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • the invention relates to a method and a composition for producing an item that can be made by forming in a mould, particularly a brick or a building panel.
  • Bricks of the known type which have to be provided with mechanical properties (for example resistance to compression) set by regulations in force, are produced from clay-based compositions.
  • the clay is mixed with water and placed in an extruding apparatus, from which an extruded product exits that consists of a continuous block of wet clay to which a preset shape has been given.
  • the extruded product is then cut into portions of a desired length and the portions are then dried and sent to a kiln to be baked.
  • the duration of which is comprised between 24 and 48 hours, it is possible to make two types of item, namely solid bricks, having a specific weight of approximately 1600-1800 kg/m 3 , and hollow bricks, having a specific weight of approximately 800 kg/m 3 .
  • a drawback of the known method is due to the significant length of the item manufacturing cycle, which is due to the time required by the drying and baking steps.
  • a further drawback associated with the high specific weight of the known bricks is that the high specific weight causes, in use, significant static loads in the buildings made through the aforementioned bricks.
  • Still another drawback of known bricks consists of the fact that, in order to lay the latter, mortar is required. This material, in addition to cementing the bricks together, enables the gaps to be closed that form between the bricks due to the substantially irregular conformation thereof.
  • mortar is an inconvenient material to manage on a building site and it substantially weakens brick structures.
  • mortar is a heat conductor, it contributes to making the bricks poor insulators against heat, with consequent formation of thermal bridges.
  • An object of the invention is to improve the known methods for producing building item, in particular bricks.
  • Another object is to provide a method for producing building items, in particular bricks, that is significantly more rapid than the known methods.
  • a further object is to provide a method for producing building items, in particular bricks, that enables the use of complicated apparatuses, such as known kilns, to be avoided.
  • Another further object is to provide a composition that is usable for producing building items, in particular bricks, having a clay content that is substantially less than that of known compositions and such as to provide the items with mechanical properties that conform to regulations in force.
  • a further other object is to supply a building item, in particular a brick, that is provided with a specific weight substantially lower than that of known items, so as to determine reduced static loads in the buildings in which it is used and to enable the loading volume of the motor vehicles by means of which it is transported to be completely exploited, thus increasing the commercial range of action of companies producing building items.
  • a still further other object is to provide a building item, in particular a brick, that is provided with insulating properties, both acoustic and thermal.
  • Still another further object is to provide a building item, in particular a brick, that can be laid without using mortar, so as to enable structures to be made that are more resistant and thermally better insulated.
  • a composition for producing a building item, comprising: finely subdivided inert materials, an alkali metal polysilicate, an oxidizing agent, formaldehyde.
  • the oxidant comprises hydrogen peroxide.
  • a method for producing a building item comprising:
  • using hydrogen peroxide as oxidizing agent is provided.
  • the item that is thus obtained is such as to produce, in use, a lighter static load than that of known items and has mechanical properties that conform to regulations in force.
  • the resistance to mechanical stresses is the same in each of the pairs of opposite faces of the item, which enables the latter to tolerate significant transverse tensions, such as occur, for example, in the event of seismic phenomena.
  • the item provided by the invention is made by pouring a fluid mixture into mould means, it is possible to obtain items, for example bricks, having a preset and, above all, regular shape. Consequently, gaps do not form when these bricks are juxtaposed to one another and it is not therefore necessary to use mortar during laying of the bricks to close these gaps. It is therefore possible to use adhesive means of the known type, for example glue for building, to lay the bricks, which enables brick structures to be obtained that are more resistant and are thermally better insulated compared with structures made by using mortar and known bricks.
  • the method provided by the invention does not involve first drying the items and then baking the items in a kiln, which enables work time to be saved and avoids the use of complicated apparatuses.
  • FIG. 1 is a schematic longitudinal section showing a step of a method for producing a building item
  • FIG. 2 is a schematic perspective view showing a further step of a method for producing a building item.
  • a mixture 1 that is usable for producing a building item 4 is obtained from a composition having an average percentage formula expressed in the following table:
  • Component % range in weight Ground inert materials 10-70 Alkali metal polysilicate 20-90 Oxidizing agent 0.1-30 Formaldehyde 0.1-30
  • the ground inert materials can be obtained by grinding fragments of clay items (broken bricks), or from clay from clay pits, which is first baked at a temperature between 600-900° C. in a rotating kiln, which is of the known type and is not shown, and is subsequently ground. In both cases, grinding is performed in such a way as to produce inert materials having granulometry comprised between 50 m ⁇ and 1 mm.
  • the inert materials may also comprise sand, ceramic sludge or other things.
  • the ground inert materials are equal to approximately 60% of the composition.
  • the alkali metal polysilicate may comprise sodium polysilicate (Na 2 O.nSiO 2 ) and/or potassium polysilicate (K 2 O.nSiO 2 ).
  • the (sodium or potassium) polysilicate is equal to approximately 40% of the composition.
  • the oxidizing agent comprises a water solution of hydrogen peroxide (H 2 O 2 ) having a 35% (130 volume) concentration.
  • the oxidizing agent is equal to approximately 5% of the composition.
  • the formaldehyde is used in the form of a water solution having a 24% concentration.
  • the formaldehyde is equal to approximately 5% of the composition.
  • a water solution of an alkali metal polysilicate for example sodium polysilicate, is used, which acts as a binder for the mixture 1 , and the ground inert materials are then dispersed in this solution.
  • an alkali metal polysilicate for example sodium polysilicate
  • oxygen is produced, which causes the increase in the volume of the mixture, and carbonic acid is produced, which reacts with the polysilicate and forms a gel that is able to solidify in a substantially rapid manner.
  • fibres added fibres to the dispersion, before the oxidizing agent and the formaldehyde, is provided, which fibres are capable of increasing the mechanical resistance of the product 4 deriving from the mixture 1 .
  • the fibres may be of vegetable origin, for example coconut or jute fibres, or be of organic origin (carbon, polypropylene) or be of inorganic origin (fibreglass).
  • adding up to 15% of polymers, for example resins, to the dispersion before the oxidizing agent and the formaldehyde is provided, which polymers are able to increase the mechanical resistance or the impermeability of the item 4 deriving from the mixture 1 .
  • adding both the fibres and polymers, before the oxidizing agent and the formaldehyde, is provided.
  • the mixture 1 once it has been prepared according to the procedure disclosed above, is poured into a cavity of a mould 2 , which reproduces the shape and dimensions of the product 4 to be made, in such a quantity as to fill the cavity 3 until it reaches a preset height H in the cavity 3 .
  • a time of approximately 15 minutes owing to the above mentioned reaction that develops between the sodium polysilicate, the oxidizing agent and the formaldehyde, the mixture 1 expands in volume, completely occupying the cavity 3 of the mould 2 , and simultaneously acquires a solid structure, thereby forming the item 4 .
  • the item 4 is extracted from the mould 2 .
  • the item 4 contains a certain percentage of free water that has to be removed and is therefore placed in an internal chamber 6 of a microwave kiln 5 ( FIG. 2 ), having specific power of approximately 1.2 KW/Kg H20 .
  • the item 4 is subjected to the action of microwaves 7 having a frequency that is preferably equal to approximately 2450 MHz, for a time that is equal to approximately 20 minutes.
  • microwaves having a frequency equal to approximately 450 MHz is provided.
  • microwaves having a frequency equal to approximately 900 MHz is provided.
  • the item 4 is completely dried and can be used directly or be suitably stored.
  • the item 4 is dried in a dryer of the thermodynamic type.
  • the latter is provided with devices (of known type) that enable environmental humidity, speed of the air flow used during drying and wet bulb temperature to be determined and controlled.
  • devices of known type
  • the most external portion of the item 4 tends to dry prematurely and to thermally isolate the internal portion of the item 4 .
  • a temperature is thus not reached that is such as to enable the water contained therein to evaporate in an effective manner.
  • the item 4 dries in an uneven and/or incomplete manner.
  • thermodynamic type By using the aforementioned dryer of thermodynamic type, on the other hand, it is possible to keep the temperature of the internal portion as close as possible to the temperature of the external portion, which substantially prevents the latter from drying prematurely. In this way, the item 4 can be dried in a homogeneous and complete manner.
  • the item 4 thus produced in addition to having mechanical properties that conform to regulations in force, has a specific weight comprised between 100 and 1000 kg/m 3 , preferably equal to 450 kg/m 3 , which specific weight is therefore significantly lower than the specific weight of known items.
  • each item 4 is regular and constant, inasmuch as they are defined by the shape and dimensions of the mould 2 .
  • glue it is not necessary to provide for the use of mortar to lay the item 4 , but it is possible to use glue.
  • brick structures can be built that are more resistant and better thermally insulated than the structures made with known bricks and mortar.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Engineering & Computer Science (AREA)
  • Geology (AREA)
  • Materials Engineering (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Environmental & Geological Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Compositions Of Oxide Ceramics (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Furnace Housings, Linings, Walls, And Ceilings (AREA)
US11/887,645 2005-04-01 2006-03-31 Method and Composition for Producing an Item Abandoned US20090030116A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
ITMO20050076 ITMO20050076A1 (it) 2005-04-01 2005-04-01 Metodo e composizione per produrre un manufatto.
ITMO2005A000076 2005-04-01
PCT/IB2006/000765 WO2006103552A2 (en) 2005-04-01 2006-03-31 Method and composition for producing an item

Publications (1)

Publication Number Publication Date
US20090030116A1 true US20090030116A1 (en) 2009-01-29

Family

ID=35431797

Family Applications (1)

Application Number Title Priority Date Filing Date
US11/887,645 Abandoned US20090030116A1 (en) 2005-04-01 2006-03-31 Method and Composition for Producing an Item

Country Status (7)

Country Link
US (1) US20090030116A1 (ja)
EP (1) EP1866258A2 (ja)
JP (1) JP2008534729A (ja)
EA (1) EA013793B1 (ja)
IL (1) IL186276A0 (ja)
IT (1) ITMO20050076A1 (ja)
WO (1) WO2006103552A2 (ja)

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3743601A (en) * 1970-11-04 1973-07-03 Fiberglas Canada Ltd Process for making silicate foams from alkali metal silicates
US3864137A (en) * 1971-12-31 1975-02-04 Bayer Ag Hydrogen peroxide blowing agent for silicate foams
US3993514A (en) * 1972-01-27 1976-11-23 Thiokol Corporation Gas generating compositions containing ammonium sulfate acceleration force desensitizer

Family Cites Families (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA946422A (en) * 1969-10-21 1974-04-30 William A. Mallow Foamed product from alkali metal silicates and process of manufacture thereof
JPS515007B1 (ja) * 1970-06-26 1976-02-17
US3856539A (en) * 1970-12-04 1974-12-24 Southwest Res Inst Solidified silica foam product and process
BE793516A (fr) * 1971-12-31 1973-06-29 Bayer Ag Production de mousses de silicates
JPS4914520A (ja) * 1972-05-20 1974-02-08
DE2227640A1 (de) * 1972-06-07 1973-12-20 Bayer Ag Verfahren zur verschaeumung von waessrigen silicatloesungen
US3933514A (en) * 1973-04-30 1976-01-20 Continental Oil Company High strength, water resistant silicate foam
US4263365A (en) * 1979-08-02 1981-04-21 John D. Brush & Co., Inc. Fire-resistant safe and panel
JPS56169194A (en) * 1980-05-28 1981-12-25 Shikoku Kaken Kogyo Kk Inorganic heat insulating layer
JPS5788060A (en) * 1980-11-12 1982-06-01 Shikoku Kaken Kogyo Kk Complex type composition
JPS5899156A (ja) * 1981-12-08 1983-06-13 大日本インキ化学工業株式会社 水ガラス発泡体の製造方法
JPS5930752A (ja) * 1982-08-12 1984-02-18 菅野　昭 歪測定用組成物
JP2696245B2 (ja) * 1989-03-24 1998-01-14 日本化学工業株式会社 珪酸アルカリ用硬化剤、それを含有する無機繊維質処理剤
US5242494A (en) * 1990-08-10 1993-09-07 British Technology Group Ltd. Foamable compositions
DE4430912A1 (de) * 1994-08-31 1996-03-07 Stefan Dr Rer Nat Geyer Wärmeisolationsmaterial
DE19522091C2 (de) * 1995-06-19 1999-08-19 Pfister Wasser- und gasdurchlässige Wege- und Flächenbefestigung hergestellt aus einer Mischung aus körnigen Zuschlagstoffen, Bindemitteln und faserförmigen Materialien bestehenden Mischung und Verfahren zur Herstellung dieser Flächenbefestigung
CA2257545C (en) * 1996-06-25 2008-12-30 Borden Chemical, Inc. Binders for cores and molds
RU2148045C1 (ru) * 1998-11-24 2000-04-27 Киселев Вадим Михайлович Сырьевая смесь для изготовления теплоизоляционного материала и способ его получения
IT1308878B1 (it) * 1999-04-28 2002-01-11 De Fatis Stefano Tabarelli Procedimento per ottenere manufatti solidi di schiuma di argilla daimpiegare nell'edilizia, e prodotti relativi.

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3743601A (en) * 1970-11-04 1973-07-03 Fiberglas Canada Ltd Process for making silicate foams from alkali metal silicates
US3864137A (en) * 1971-12-31 1975-02-04 Bayer Ag Hydrogen peroxide blowing agent for silicate foams
US3993514A (en) * 1972-01-27 1976-11-23 Thiokol Corporation Gas generating compositions containing ammonium sulfate acceleration force desensitizer

Also Published As

Publication number Publication date
JP2008534729A (ja) 2008-08-28
WO2006103552A8 (en) 2007-12-13
EA013793B1 (ru) 2010-06-30
IL186276A0 (en) 2008-01-20
ITMO20050076A1 (it) 2006-10-02
WO2006103552A2 (en) 2006-10-05
WO2006103552A3 (en) 2006-11-23
EP1866258A2 (en) 2007-12-19
EA200702142A1 (ru) 2008-04-28

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AS Assignment

Owner name: KEIPER HOLDING S.R.L., ITALY

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:DI GIROLAMO, RAFFAELLA;REEL/FRAME:020315/0079

Effective date: 20071119

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Owner name: EUREKA PROJEKT SOCIETA A RESPONSABILITA LIMITATA P

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:KEIPER HOLDING S.R.L.;REEL/FRAME:021321/0279

Effective date: 20080708

STCB Information on status: application discontinuation

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